Compositionally Grading Alloy Stacking Fault Energy using Autonomous Path Planning and Additive Manufacturing with Elemental Powders

Abstract: Compositionally graded alloys (CGAs) are often proposed for use in structural components where the combination of two or more alloys within a single part can yield substantial enhancement in performance and functionality. For these applications, numerous design methodologies have been developed, one of the most sophisticated being the application of path planning algorithms originally designed for robotics to solve CGA design problems. In addition to the traditional application to structural components, this work proposes and demonstrates the application of this CGA design framework to rapid alloy design, synthesis, and characterization. A composition gradient in the CoCrFeNi alloy space was planned between the maximum and minimum stacking fault energy (SFE) as predicted by a previously developed model in a face-centered cubic (FCC) high entropy alloy (HEA) space. The path was designed to be monotonic in SFE and avoid regions that did not meet FCC phase fraction and solidification range constraints predicted by CALculation of PHAse Diagrams (CALPHAD). Compositions from the path were selected to produce a linear gradient in SFE, and the CGA was built using laser directed energy deposition (L-DED). The resulting gradient was characterized for microstructure and mechanical properties, including hardness, elastic modulus, and strain rate sensitivity. Despite being predicted to contain a single FCC phase throughout the gradient, part of the CGA underwent a martensitic transformation, thereby demonstrating a limitation of using equilibrium CALPHAD calculations for phase stability predictions. More broadly, this demonstrates the ability of the methods employed to bring attention to blind spots in alloy models.